Structural corner post

ABSTRACT

The building structure utilizes prefabricated frame components of equal heights in forming the external and internal framing systems. The basic frame components include a structural post, blank wall frames, window frames, door frames and end caps. Each of the frame components is elongated and is provided with a laterally extending elongated male connector along one vertical edge and a pair of horizontally extending structural members at the top and bottom of the frame component forming a female receptacle on the other vertical edge whereby the male connector on each of the frame components fits into the female receptacle on an adjacent frame component and is secured thereto. Each frame component has load bearing capabilities and may be used interchangeably as members of interior or exterior walls. Each frame component utilizes manufactured elements which are commercially available and which require a minimum amount of work thereon, if any, in order to utilize same in the frame components. Identical manufactured parts are utilized in assembling the frame components and there is a regular rhythm of spacing the vertical studs or members of the frame components to insure &#39;&#39;&#39;&#39;on center&#39;&#39;&#39;&#39; dimensions when compared with present panel constructions. In erecting the frame components, there is a constant repetition of identical components with the male connector of one component mating with a female receptacle on adjacent components and thereafter the components are tied mechanically together. Outer sheathing and inner wall boards are secured to the external and internal frame structures. Ceiling boards are secured to the roof trusses provided on the framing system.

United States Patent [191 Matuschek et al.

[ 1 Apr. 15, 1975 STRUCTURAL CORNER POST [75] Inventors: Richard W.Matuschek,

Birmingham; William Garth, Jr., Sterling Heights, both of Mich.

[73] Assignee: Univiron Corporation, Southfield,

Mich.

[22] Filed: June 6, 1973 [21] Appl. No.: 367,370

Related U.S. Application Data [62] Division of Ser. No. 254,031, May 17,1972, Pat. No.

[52] U.S. Cl. 52/730; 52/301; 52/494; 52/732 [51] Int. Cl. E04c 3/36[58] Field of Search 52/280, 497, 586, 593,

[56] References Cited UNITED STATES PATENTS 1,236,635 8/1917 Wells52/280 X 2,065,433 12/1936 Dercum et al..... 52/281 X 2,363,862 11/1944Hancock 52/497 X 2,521,381 9/1950 Linch 52/280 X 2,836,861 6/1958Rethmeier 52/732 X 3,206,903 9/1965 Johnson 52/494 X 3,226,906 1/1966Koerner 52/732 3,305,986 2/1967 Mathews 52/730 X 3,462,897 8/1969Weinrott 52/285 X 3,466,821 9/1969 OShaughnessy et a1. 52/593 X3,665,662 5/1972 Timbrook et al. 52/281 X FOREIGN PATENTS ORAPPLICATIONS 1,194,551 6/1965 Germany 52/497 1,484,122 l/1969 Germany52/592 Primary Examiner-Frank L. Abbott Assistant Examiner-Leslie A.Braun Attorney, Agent, or Firm-Cullen, Settle, Sloman & Cantor [57]ABSTRACT The building structure utilizes prefabricated frame componentsof equal heights in forming the external and internal framing systems.The basic frame components include a structural post, blank wall frames,window frames, door frames and end caps. Each of the frame components iselongated and is provided with a laterally extending elongated maleconnector along one vertical edge and a pair of horizontally extendingstructural members at the top and bottom of the frame component forminga female receptacle on the other vertical edge whereby the maleconnector on each of the frame components fits into the femalereceptacle on an adjacent frame component and is secured thereto. Eachframe component has load bearing capabilities and may be usedinterchangeably as members of interior or exterior walls. Each framecomponent utilizes manufactured elements which are commerciallyavailable and which require a minimum amount of work thereon, if any, inorder to utilize same in the frame components. Identical manufacturedparts are utilized in assembling the frame components and there is aregular rhythm of spacing the vertical studs or members of the framecomponents to insure on center dimensions when compared with presentpanel constructions.

In erecting the frame components, there is a constant repetition ofidentical components with the male connector of one component matingwith a female receptacle on adjacent components and thereafter thecomponents are tied mechanically together. Outer sheathing and innerwall boards are secured to the external and internal frame structures.Ceiling boards are secured to the roof trusses provided on the framingsystem.

4 Claims, 16 Drawing Figures PATENIEDA RI B S 3.877. 194 sum u gr: {5

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PATENIED R I 19- 5 3,877. 194

SHEETSUF8 FIGJO FIG.9

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FIGJZ STRUCTURAL CORNER POST This is a division of application Ser. No.254.031, filed May 17. 1972 now U.S. Pat. No. 3,774,362.

BACKGROUND OF THE INVENTION During the past decade there have beenprograms designed for lowering the cost of constructing buildings. Theemphasis of such programs is placed primarily on buildings designed forresidential use. Individual entrepreneurs as well as large industrialand commercial firms have attempted to find solutions to the problem ofconstructing economical buildings and houses. The avowed objective ofeach program is to produce a bet ter house for less cost.

The term manufactured housing" has been used during the last severalyears. The basic assumption is that only by building houses in factoriescan solutions be found to rising costs. Such an assumption indicates amisunderstanding of the term manufactured housing as well as itsmeaning. It is submitted that houses cannot be manufactured any morethan an automobile or a toaster is manufactured. Automobiles andtoasters are assembled from parts that are manufactured. Thus buildingsand houses are assembled and not manufactured.

Only parts can be manufactured i.e. made by machine. Only a high volumeof identical parts makes manufacturing economical. Manual operations arerarely replaced by a machine operation until the market for such partsmade by man reach a potential volume that will not only provide a returnon the invest ment in the machine but in addition will yield a profit.

The basic problem with housing is not that there is too littlemanufacturing; but, too much. Every single component that a houserequires is already being man ufactured in factories. Too frequentlythese products are simply manufacturing blanks in the hands of thebuilder and the subcontractors who practice their craft byre-manufacturing with their ancient hand tools what machines produced.Some products are used in a house precisely as they were manufactured orfactoryassembled, products such as nails, switch plate covers, toilets,appliances and doorknobs. But the products that are used in framing thehouse and covering the frame are typically measured, marked, and cut.Until then the 2 X 4 inches lumber, gypsum board, insulation batt andexterior siding may never have been handled by man. Even such a mundaneitem as a pine 2 X 4 inches is a product of a capital-intensive, highlysophisticated processing industry and it comes to the carpenter in a farmore finished, dimensionally true state than its hand-hewn predecessordid not too many years ago. However, by the time the carpenter isfinished measuring, marking, sawing, drilling, notching, routing,shimming and otherwise remaking the lumber, much of the manufacturingeconomies inherent in that piece of lumber are lost. A person rarelyfinds a high enough quantity of such parts in a house that are preciselyidentical to attract somebody to manufacture the parts in final form.

It is on individual parts that the present invention focases. If housingis to be revolutionized", the emphasis must be placed on every singlecomponent that goes into the production of the building. Only byoffering industry high volume of identical parts can housing attract theinvestment required for even more sophisticated machines than arepresently available; lure technologies that exist but are not beingapplied to housing; and unleash the research and developmentexpenditures that must be forthcoming if housing is to catch up with atleast the machine, if not the space age.

Most manufactured housing firms concentrate almost exclusively on tryingto achieve substantial labor savings vis-a-vis conventional, on-siteconstruction. The techniques used, however, are usually limited tohiring non-skilled" workmen so that lower'than-field wages can be paid.The materials being used and the methods of fabrication are customarilythe same as one finds on a conventional building site. There are severalfallacies in this approach. Among them. as discussed hereinafter, is theassumption that reducing labor costs alone will more than offset theinvestment and cost penalties that builders incur when they elect tobuild houses in factories. These cost or investment penalties versusconventional construction firms come in the form of land and buildingfor the plant; tooling; administrative and production overhead; specialfreight problems and costs; and, the unique unique for the constructionindustry problem of having to selffinance their entire inventory.Perhaps the most serious but least acknowledged penalty comes in theform of restrictions on design. The manufactured house is frequently sounattractive aesthetically that it borders on being non-competitive atany price.

The most serious error that housing manufacturers typically make isexaggerating labors share of the total cost of construction. Analyses bythe Kaiser Commission outline construction costs of single-familyresidences as: labor 18 percent; material 38 percent; development 30percent; overhead and profit 14 percent; for a total lOO percent.

By extrapolation, the analysis suggests that 8 percent of the 18 percentlabor input is associated directly with development, e.g. excavating andbuilding foundations, back-filling, hooking up utilities. The balance oflabor costs only 10 percent of total costs is associated directly withthe structure; only this portion can be moved into a plant. Even ifin-plant operatons could yield a 50 percent reduction in labor costs,the net impact on total costs would be only 5 percent. The effect ontotal monthly occupancy costs is even less impressive. A 50 percentreduction in house-related labor would lower a homeownersmonthly costsby less than 3 percent. In search of such savings, however, it is commonto make a substantial investment in plant, tooling and equipment. Thesecosts, plus the other cost penalties referred to earlier, are severehandicaps for the housing manufacturer because they are all in excess ofwhat his competitor the traditional builder has invested. Justamortizing the investment and paying for the high overhead (again,relative to his competition) will more than offset any labor savings,and it is not clear whether he is even achieving the latter.

Because of inadequate analysis of the trade-offs between the immenseinvestment in plant and (theoretical) labor savings, large losses havebeen experienced by otherwise capably managed companies who haveventured into manufactured housing. Many have ceased to do business inthe housing field because of serious financial losses.

There are two principal categories of firms which are attempting tobuild houses in factories: (a) those which assemble the entire house inthe factory, usually in two sections, truck it to a site, set it on itsfoundation, and make final connections; and (b) those classified ascomponent manufacturers; the latter customarily take one of two forms,or perform both types of operations:

1. Component manufacturers fabricate whole walls, complete withinsulation and wiring, windows and doors. and exterior and interior wallsheathing installed in the factory. Usually cranes are required forfinal assembly of the wall components on site; and

2. Other component manufacturers fabricate smaller sections of the wall,usually referred to as panel manufacturers, with sheathing, insulation,wiring and exterior siding left for installation on site.

The latter type of operation is most akin to the subject invention inthe sense that the product of such a component manufacturer typicallyfollows a modular scale. The panels usually are offered in lengths suchas 2 foot, 4 foot, and 8 foot. Such panels are, however, usually closedat both ends. As a result, there are material cost penalties since thereis a doubling up of end studs where two panels abut. Also, this typeofjoint and internal assembly complicates their assembly and theengineering of assembly tools and processes. The main reason is that aregular rhythm of spacing between studs is not maintained; i.e. oncenter dimensions are not constant. This kind of a butt joint alsorequires in some applications special efforts to insulate the butt seam.Of course, manufacturing and assembly econo mies are reduced to theirlowest level by those panel fabricators who build any size panel that acustomer may choose to specify.

SUMMARY OF THE INVENTION This invention relates to the use ofprefabricated frame components used in the erection of the internal andexternal framing systems of houses, low-rise apartments, officebuildings, light industrial buildings and schools.

The basic framing components include a structural column or corner post,blank wall assemblies or wall frames, window frames and door frames andend caps. The framing structure or system utilizes top and bottomhorizontal framing parts (plates) that are of the same dimension.Vertical support members or studs are located on center and vary inlength only when used to support sills in windows or door frames. Eachof these components has load-bearing capabilities and may be used asmembers of interior or exterior walls, interchangeably.

Corner support and structural integrity are provided by the column orcorner post designed to receive the male end of the framing componentfrom one side and, at a 90 angle to the male, a female end of anotherframing member or component. The corner post may be reversed, i.e.,turned upside down, and used for a reverse configuration of wallmembers. This permits the same column or corner post to be used forinside or outside corners without modifications required for the columnor the sub-assemblies that abut it. The same corner post withoutmodifications is also used in certain applications for joiningintersecting members of interior walls. Any one of the framing membersor components may be connected at right angles to any other by simplyinserting the male end or connector anywhere next to or between thevertical members along the horizontal plane of the member or componentwhich it is joining or by abutting the female end to the member orcomponent anywhere along the horizontal plane. The end cap is used toclose the female end or female receptacle of a wall member or framecomponent as may be required in some applications. It is identical inlength to the vertical supports or studs used in the frame components.

The various frame components are joined together via a C-type butt jointon the horizontal plane that overlaps a vertical support member or studboth at the top and bottom. Various frame components are connectedtogether with the conventional top plate, each section of which wouldbutt approximately 12 inches or more from any butt joint formed by thewall members or frame components.

The framing system requires as few as eight different parts from whichall components can be assembled, namely the post, blank wall members,window frames, door frames, and the end caps. The system includes aconstant repetition of identical parts which are manufactured in volume.Use of identical parts is the absolute prerequisite for economicalmanufacturing. Production capability is increased since eight machines,very simple in design, could be used to make the eight parts. Toolingcosts would be minimized since each machine performs only one operation,which typifies the least expensive and most efficient machine of all.

In the framing system there is a regular rhythm of spacing between fulllength, vertical wall members or components which makes assemblyparticularly easy. Sheathing may be applied to the framing system withvirtually no modification required in most instances. This permitsmanufactured materials such as the typical 4 X 8 foot gypsum andinsulation-type wall boards to be used as finished products on theframing system without alterations.

Another feature of the present invention is that the framing members maybe produced economically either in a plant, where the advantage may beproduction and inventory control, or on the building site. In additionthe system is equally adaptable to a conventional stick building, aswell as the typical in-plant type of operation. Depending on the size ofthe structure, a building could be enclosed on the site within one daythus permitting some flattening of the building cycle that results fromclimatic conditions and tend, therefore, to increase the overallproductivity of the housing industry.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of ahouse or building structure;

FIG. 2 is a fragmentary perspective view of a corner of another house orbuilding structure, with certain parts removed or broken away toillustrate the external framing structure;

FIG. 3 is a fragmentary perspective view of another house or buildingstructure, with certain parts removed illustrating the internal andexternal framing structures;

FIG. 4 is an exploded fragmentary view illustrating the manner in whicha pair of framing units located at are joined together by a C-type buttjoint or malefemale connection;

FIG. 5 is an exploded perspective view illustrating a corner post and aplurality of framing components or units of the framing structure priorto being joined together;

FIG. 6 is a fragmentary perspective view of the upper portion of thecorner post illustrating the method of connecting two adjacent framecomponents to the corner post.

FIG. 7 is a fragmentary perspective view of the lower portion of thecorner post illustrating the manner in which the two adjacent framecomponents are con nected to the corner post;

FIG. 8 is a perspective view of the window frame;

FIG. 9 is a perspective view illustrating the manner in which a pair ofangularly related frame components, one internal and one external, areconnected;

FIG. 10 is a perspective view illustrating the manner in which aninternal door frame is joined to an internal or external wall frame;

FIG 11 is a sectional view through the corner post taken on the line11-11 of FIG. 5;

FIG. 12 is an enlarged fragmentary view of a corner construction, withintermediate parts of the corner post and horizontal framing membersbroken away, showing the upper and lower horizontal framing membersattached to the corner post;

FIG., 13 is a vertical sectional view through a wall frame illustratingthe manner in which the outer sheathings, inner wall board and ceilingpanel are mounted in the framing system;

FIG. 14 is a plan view of another house or building structureillustrating the manner in which the outer sheathing and inner wallboards are attached to the framing components; and

FIG. 15 is an enlarged fragmentary plan view of one corner of the houseor building structure illustrated in FIG. 14; and

FIG. 16 is a fragmentary front elevational view of a modified frameconstruction for a large window opening or for a sliding door andincluding upper and lower horizontal bridge or spanner elements.

DESCRIPTION OF A PREFERRED EMBODIMENT The house or building structureillustrated in FIG. 1 is designated by the numeral 10 and the house orbuilding structure illustrated in FIGS. 2 and 3 is designated by thenumeral 11. The fabricated structural frame components including columnsand panels, described in detail below, utilized in the buildingstructures 10 and 11 are interchangeable and can be arranged to pro videbuilding structures of various configurations and sizes.

The building structure 10, 11 is erected or assembled on a generallyflat and hard surface such as a concrete slab 12. The building structure10, 11 includes a continuous or endless external framing structure 14and also may include an internal framing structure 16, as an example, ofthe type illustrated in FIG. 3. The external framing structure 14 isprovided with suitable sheathing 18 on the outside surface of theframing structure 14 as will be subsequently described. In addition,suitable wall panels 20 are provided on the inside of the externalframing structure 14 and on both sides of the internal framing structure16.

Mounted on the external framing structure 14 of each building structure10, 11 are roof trusses 22 spaced, as an example, on 24 inch centers.Each roof truss 22 comprises a horizontal stringer 24 and a pair ofinclined structural members 26 suitably connected at the center apex atthe inner ends thereof and to opposite end portions of the stringer 24at the outer ends thereof to provide a gable type roof structure ortruss 22. Roof boards 28 are mounted on the roof trusses 22 to which isapplied a suitable roofing material 30 (FIG. I) such as asbestosshingles. It should be appreciated that the roof structure may takevarious shapes and be made from various materials well known in the art.

Referring now to FIGS. 1, 2, 3 and 5 the external framing structure 14consists of a plurality of standardized frames and componentshereinafter referred to as the column or corner post 34, window frame36, wall frame 38 and door frame 40. The aforementioned corner post 34,window frame 36 and wall frame 38 are also used in forming the internalframing structure 16. The only difference between the internal andexternal framing structure 14 and 16 is in the design of the door frameand in the use of end caps as will subsequently appear.

FIGS. 5-11 inclusive illustrate five standardized frame componentsutilized in the internal and external framing structures 14 and 16. Thecolumn corner post 34 as illustrated in FIGS. 57, 11 and 12 consists ofthree elongated vertical studs 44, 46 and 48, of equal length, with twoof the studs 44, 46 arranged parallel and spaced slightly apart adistance of one-fourth inch. The other stud 48 abuts the two parallelstuds 44, 46 as shown in FIG. 7. The column 34 further includes an upperend cap or plate 50 and a lower end cap or plate 52 which are secured tothe top and bottom surfaces of the column 34 respectively. Onelongitudinal and vertical edge portion of the column 34 forms a maleconnector 54 while another edge portion of the column 34, defined by theoverhanging portions 56, 58 of the end caps 50, 52 respectively, forms afemale receptacle 60 located at 90 from the male connector 54. The maleconnector 54 has an upper flat surface 62 and a lower flat surface 64.The male connector 54 has a length equal to the length of stud 48. Thefemale receptacle 60 has a height equal to the length of stud 46 whichhas a surface 66 which defines the back wall of the receptacle 60.

As shown in FIG. 8, each window frame 36 consists of a pair of verticalstuds 70; a bottom horizontal plate 72; a pair of intermediatehorizontally extending elements or sills 74, 76, which define along withintermediate portions of said vertical studs 70 a window opening a pairof vertical bracing elements or studs 82 interposed between the lowerintermediate horizontal element 76 and the bottom horizontal plate 72; aheader 84 consisting of two elements 86 laid on their edges and spacedapart and mounted on top of the vertical studs 70; and a top horizontalplate 88 mounted on the header 84: As illustrated in FIG. 8 theleft-hand vertical edge of the window frame 36 forms an elongated maleconnector 90. The overhanging portions of the plates 72 and 88 at theright-hand vertical edge portion of the window frame 36 and the outersurface of the right stud 70 and the right end surface of header 84forms a female receptacle 92 which is adapted to receive the maleconnector on a column or corner post 34 or the male connector on anadjacent frame whether a window frame 36, wall frame 38, or door frame40. The bracing studs 82 are located on 16 inch centers with respect tothe studs 70. The size of the window opening 80 may vary.

As shown in FIG. 5, each wall frame 38 comprises three verticallyextending studs 94 spaced on 16 inch centers". a bottom horizontallyextending plate 96; and a top horizontally extending plate 98. The topand bottom plates 96, 98 are of equal length and are connected to thethree vertically extending studs 94 as shown in FIGS. 5, 9 and 10. Theleft-hand longitudinal edge of the wall frame 38 as shown in FIG. formsa male con nector 100. The overhanging end portions of plates 96, 98 atthe right-hand edge portion of the frame 38 forms a female receptacle102 which is adapted to receive the male connector on a column or cornerpost 34 or the male connector on an adjacent frame whether a windowframe 36, wall frame 38, or door frame 40. The wall frame 38 may be usedin both the internal and external framing systems.

As shown in FIG. 5, the external door frame consists of a pair ofvertical stiles 105, 106, each stile 105, I06 consisting of an innervertical stud 108 and an outer vertical stud 110. The inner verticalstud 108 is shorter than the outer vertical stud 110. The vertical studs108, 110 of each stile are spaced apart 1V2 inches. The vertical studs108, 110 of the left stile are mounted on an end cap or plate 112 whilethe vertical studs of the right stile 106 are mounted on a larger endcap or plate 114. An intermediate horizontal element 116 spans the spacebetween and abuts the inner surfaces of the outer vertical studs and issecured to the top surfaces of the inner vertical studs 108. A header118 consisting of two horizontally extending elements or parts 119 arespaced apart one-half inch and are mounted on their edges across the topsurfaces of the outer vertical studs 110 of the two stiles 105, 106. Atop horizontal plate 120 is supported by the header 118. The left-handedge of the door frame 40 forms a male connector 122. The overhangingend portions of end plate 114 and top plate 120 and the outer surface ofstud 110 of the stile 106 at the right-hand edge of the door frame 40(FIG. 5) forms a female receptacle 124 which is adapted to receive themale connector on a column or corner post 34 of the male connector on anadjacent frame whether a window frame 36, wall frame 38 or door frame40.

As shown in FIGS. 3 and 10, the internal door frame consists of a pairof vertical stiles 132, 134, each stile 132, 134 consisting of an innervertical stud 136 and an outer vertical stud 138. The inner verticalstud 136 is shorter than the outer vertical stud 138. The vertical studs136, 138 of each stile are spaced apart. The vertical studs 136, 138 ofthe left stile 132 are mounted on an end cap 140 while the verticalstuds of the right stile 134 are mounted on a larger end cap 142. Anintermediate horizontal element or plate 144 spans the space between theouter vertical studs 138 and is secured to the top surfaces ofthe innervertical studs 136. A top horizontal plate 146 is mounted on the outervertical studs 138. A bracing stud 148 is centrally located betweenstuds 138 between the horizontal plates 144, 146. The left-hand edge ofthe internal door frame 130 forms a male connector, not shown. Theoverhanging end portions of plate 146 and end cap 142 and the outersurface of stud 138 of stile 134 at the right-hand edge of door frame130 forms a female receptacle 150 which is adapted to receive the maleconnector on a column or corner post 34 or the male connector on anadjacent frame.

The various frame components as stated previously are erected andassembled on slab 12, with the door frames, window frames, wall framesand corner posts of the internal and external framing systems locatedaccording to the floor plan. After the various components are erected onthe slab l2 horizontal top plates are placed on top of the several framecomponents of the internal and external framing systems 14, 16. As shownin FIGS. 2 and 3, the top of plates 160 are superimposed on the tophorizontal structural members of the frame components includingstructural members 120, 98, 88, 130, etc. Thereafter the conventionaltop plates 160 are secured to the frame components including the cornerposts to tie the frame components together. The roof trusses 22 aremounted on the framing system and spaced on 24 inch centers as statedpreviously. Each gable type building structure includes various wallboards and sheathing at the ends of the building struc-' ture betweenthe top plates 160 and the roof structure as represented generally bythe numeral 162 in FIG. 1.

FIG. 3 illustrates the male-female connections or C- type butt jointsprovided between adjacent wall components, with the conventional topplates 160 spanning the exterior framing structure 14 as well as theinterior framing structure 16. Each top plate 160 has a cross section of1% X 3 /2 inches and can vary in length. Each wall component has aheight of 7 feet 1 1 inches. The overall height from the slab 12 to thetop surface of plate 160 is 8 feet A2 inches.

As stated previously, the present invention utilizes certain partsmanufactured in volume from commercially available lumber. Severalcomponent parts having a predetermined length and cross section are usedfor economy purposes. The component parts of each frame component aretied together by nails. Abutting frame components also are tied togetherby nails which are driven through the C-type butt connection as appearsin FIG. 12. The top plates 160 are tied to the frame components by nailsproperly placed.

The dimensional configuration of the several parts used in themanufacture of the frame components are as follows:

Wall Frame 38 Continued No. Section Length vertical studs )4 l- /z" X 347'8" bottom plate )6 do. 4'0" top plate 98 do. 4'0" External Door Frame-10 (4% wide) 71 1" outer vertical studs l H) l-" X 3- /3" 7Z-V.:" innervertical studs I08 do. o'l0- /4" intermediate plate 1 16 do. 3")" topplate 121) do. 4'0" header members 1 I 18 l- X S A" 4'0" left bottom endcap l 12 3- /1" X 3 /4 l-'/ thick right bottom end cup 1 l4 3-A" X 5%"l- /g" thick lnternul Door Frame 130 (4% wide) 7'1 1" outer verticalstuds I38 l /z" X 3- /2" 7'8" inner vertical studs 136 do. b'lO-W'intermediate plate I44 do. 3'9" top plate 146 do. 4'0" center hracc 148do. 7"/4" left bottom end cap 140 3 X 5-V4" l- /fthick right bottom endcap 142 3- /2" X (1 l-V- "thick Vertical End Cup 94' l-/;" X 3- /1" 7'8FIGS. 13-15 inclusive illustrate the structure for as sembling the outersheathing l8 and the inner wall boards to the frame components of theinternal and external framing systems 14, 16. The outer sheathing 18 iscommercially available in sheets of a size 4 X 8 foot X /2 inch. Thesheathing 18 is erected or applied to the framing system 14 withvirtually no modification required in most cases except to fit arounddoor and window openings. The wall boards 20, as an example, gypsum andinsulation-type wall boards, are commercially available in 4 X 8 foot X/2 inch sheets. The wall boards 20 are used as purchased with theexception when applied to door frames and window frames. In suchinstances the boards must be cut to required size.

It will be noted in FIG. 12 that after a pair of angularly relatedstructural members 98 of adjacent wall frames 38 are tied to the cornerpost 34, the inner corner 166 of the upper end plate 50 and the innercorner 168 of the lower end cap 52 of corner post 34 are exposed andeach provides a pair of vertical surfaces 170, 172 located at 90. Suchsurfaces 170, 172 each has a height of 1 /2 inches and a width ofone-half inch and forms a stop surface for the inner wall boards 20 asillustrated in FIGS. 14 and 15.

The vertical surfaces 170, 172 on the corner posts 34 and the verticalstuds of the several frame components provide nailing surfaces in orderto connect the outer sheathing or sheets 18 and the inner wall boards 20to the frame components. The sheathing and wall boards are manufacturedin 4 X 8 foot X /2 inch sheets. The boards may be arranged vertically asillustrated in FlG. 13 or horizontally. In FIGS. 13 the outer sheathing18 extends from the ground or slab 12 to a point one-half inch below thetop surface of the conventional top plate 160. The wall board 20 alsoextends from the slab 12 to one-half inch below the top surface of thetop plate 160. The outer sheathings 18 are connected to the verticalstuds of the frame components which are located on 16 inch centers. Thewall boards 20 abut the vertical surfaces 170, 172 of the corner posts34 and are connected to the vertical studs of the frame components.Since the vertical studs of the internal and external framing systems14, 16 are accurately located on 16 inch centers, the workman needs onlyto measure from the corner posts along each wall after the sheathings l8and wall boards 20 are put in place in order to locate the verticalnailing surfaces provided on the vertical studs. The ceiling board 180illustrated in FIG. 13 is in the form of a 4 X 8 foot X /2 inch sheet.The ceiling boards 180 abut the horizontal stringers 24 provided on thetrusses 22. The edges of the ceiling boards 180 abut the top edges ofthe wall boards 20, with the outer surfaces of the ceiling boards 180being flush with the outer surface of the top plates 160. The ceilingboards 180 may be secured to the horizontal stringers 24, located on 24inches centers, by nails.

Vertical end caps 94 are utilized to close the female ends of the wallframes 38 as illustrated in FIG. 14. In addition, end caps 94' areprovided in certain applications where the female ends of two or moreinterior or exterior wall frames 38 come together and where the femaleend of a wall frame 38 connects to the exterior framing system. FIGS. 14and 15 illustrate the manner of using nails 182 to attach the outersheathings l8 and wall boards 20 to the vertical studs of the interiorand external framing systems l4, 16.

The blank wall frame 38 may be modified and designed to meet a localbuilding code which permits stud-wall construction on 24 inch centersrather than 16 inch centers as described previously. The configura tionof the other frame components, i.e. wall, door, corner post and end capswould remain the same. The only difference would be that the verticalstuds of the frame components would be increased in length or extended 1/2 inches. With such a construction the conventional top plates areeliminated in both the internal and external framing systems. Tocompensate for the removal of the 1 /2 inch top plate 160 and stillmaintain a rough wall height of 8 feet /2 inch (to accommodateconventional manufactured wall covering materials which commonly come inincrements of 4 foot widths, 8 foot lengths and one-half inchthickness), the vertical studs of each frame component would belengthened by 1 /2 inches.

The 24 inch on-center pattern is gaining acceptance in the United Statesas members of the building trades seek effective ways of loweringconstruction costs without sacrificing structural integrity. With floorjoists, wall studs and roof trusses all on 24 inch centers a rhythmicband of structural members rings the entire building. The present systemis readily adaptable to this trend. A material cost reduction wouldresult since the top plates 160 are eliminated in addition to one studper each 4 foot blank wall frame. The roof trusses, located on 24 inchcenters, would rest directly on the frame components.

When properly fabricated and erected the system would permit framing-inan entire structure of approximately 1500'2000 square feet within 1 day.Most importantly framing the walls, both interior and exterior,

could be accomplished with little more than a hammer. When preciselymade, components of the system square and plumb each other at time ofconnecting together. The entire wall structure can be erected with out ameasuring tool or marking device, a saw, a drill, or a square; therebyseveral of the most labor-intensive activities associated with buildingconstruction are eliminated. Theoretically, even a level may beunnecessary except as a quality control gauge.

The use of the framing system is not dependent upon the availability ofany particular building material. As a result, the framing system couldbe constructed from any material that has load-bearing characteristicsthat may be found locally. The framing system need not be assembled byskilled tradesmen since it is particularly useful for self-help buildingprojects or for building in areas where there is a short supply ofbuilding tradesmen.

Dimensionally, the framing system is sized to accept conventional wallcovering materials such as gypsum board and exterior sheathing with aminimum of modification to such products; also, to accept conventionalplumbing and electrical components; and at the same time, theengineering principles incorporated make the framing system adaptable tochange that may subsequently occur in any one of the frame componentswhich require the frame for support. The vertical supports or studs canbe moved closer or further apart, the plate can be lengthened orshortened or altered in oher ways, as can the vertical members, in widthor any other dimension, without departing from the basic concept of theinvention.

The framing system incorporates a high degree of dimensionalstandardization, and thus lends itself readily to the design andbuilding of simple tools for fabricating its members and for assemblingits parts.

The costs of both material and labor for framing in a house or othertype of building structure should be equal to or less than forconventional constructions. The framing system due in part to usingmanufactured parts and by locating the studs on center provides a betterstructure in terms of strength and the structure is adapted to beexpanded without costly probing of the walls to determine studlocations. In addition the framing system permits the exchange of anyone of its framing members for another (or simply interchanging existingmembers).

The variety of local and state building codes in the United States isconsidered to be a major obstacle in aggregating a national housingmarket from which could be derived the maximum economies available frommanufacturing. With the present framing system the most stringentstructural building codes in the United States as well as in neighboringcountries would be met. Thus the system is universally applicable,without alienating local building departments, zoning boards, or tradeunions. Due to its open type construction, the framing systemaccommodates state and local electrical or mechanical constructioncodes.

The frame construction 200 illustrated in FIG. 16 may be used in thebuilding structure where a large picture type window opening or asliding door construction is required. The frame construction 200includes portions ofa pair of wall frames 38 which are separated by anupper bridge or spanner device 204 and by a lower spanner element 205.The end portions 206 of the top and bottom plates 96, 98 of the leftwall frame 38 overhang a distance of feet from vertical stud 94. Thevertical stud 94 of the right wall frame 38 extends or overhangs adistance of three-fourths inches.

The bridge or spanner 204 includes a pair of elongated header members208 which are spaced apart. Each member 208 is constructed from 2 X 6wood lumber and has an actual size of 1 /2 X 5 /2 X 5 feet 2% inches. Atop plate 210 is mounted on the header members 208, with the right endportion 212 overhanging a distance of three-fourths inches whereby theend portion 212 is adapted to rest upon the top surface of stud 94 ofthe right wall frame 38. The top plate 210 is made of 2 X 4 wood lumber,having an actual size of 1 /2 X 3 /2 inches X 4 feet. The left endportions 212 of header members 208 are not covered by the top plate 210and are adapted to fit under the overhanging portion 206 of top plate 98of the left wall frame 28 and to be secured thereto.

The lower spanner device 205 is made from 2 X 4 lumber and has an actualsize of 1 /1 X 3 /2 inches X 4 feet. The right end portion of the lowerspanner device 205 abuts the lower surface of the vertical stud 94 ofthe right wall frame 38. The end portion 206 of the lower plate 96 ofthe left wall frame 38 is adapted to abut the end surface of the lowerspanner 205 and is secured or connected thereto by various types offastening or connecting devices or braces, not shown.

What we claim as our invention is:

1. A load supporting corner post adapted for use in the framing systemof a building structure comprising a vertically extending elongatedcolumn, the top and bottom surfaces of said column being flat andparallel, each of said top and bottom surfaces being divided into firstand second zones, and upper and lower generally flat end caps overlyingand secured to the first zones of said top and bottom surfacesrespectively in parallel relation and extending in the same direction,and end caps including vertically aligned overhanging edge portionswhich form a female receptacle with an adjacent and intermediatevertical surface on said column, said female receptacle being adapted toreceive therebetween a vertical structural member, the second zones ofsaid top and bottom surfaces overlying a laterally extending verticaledge portion of said column which form a male connector which is adaptedfor engagement with the end portions of upper and lower horizontallyextending structural members, said vertical edge portion and saidintermediate vertical surface being located apart, said columncomprising a pair of longitudinally extending structural elementsarranged in parallel relation having the opposing longitudinal surfacesspaced slightly apart and a third longitudinally extending structuralelement abutting and arranged perpendicular to said pair of structuralelements, said pair and said third structural elements being ofsubstantially equal length, said third structural element forming saidlaterally extending vertical edge portion.

2. The load supporting corner post defined in claim 1 wherein said upperand lower generally flat end caps each has a horizontal cross section ofrectangular configuration.

3. The load supporting corner post defined in claim 1 wherein saidstructural elements and said end caps are made from wood.

4. The load supporting corner post defined in claim 3 wherein the endcaps are secured to the column by nails driven through the end caps andfirst zones into the column.

1. A load supporting corner post adapted for use in the framing systemof a building structure comprising a vertically extending elongatedcolumn, the top and bottom surfaces of said column being flat andparallel, each of said top and bottom surfaces being divided into firstand second zones, and upper and lower generally flat end caps overlyingand secured to the first zones of said top and bottom surfacesrespectively in parallel relation and extending in the same direction,and end caps including vertically aligned overhanging edge portionswhich form a female receptacle with an adjacent and intermediatevertical surface on said column, said female receptacle being adapted toreceive therebetween a vertical structural member, the second zones ofsaid top and bottom surfaces overlying a laterally extending verticaledge portion of said column which form a male connector which is adaptedfor engagement with the end portions of upper and lower horizontallyextending structural members, said vertical edge portion and saidintermediate vertical surface being located 90* apart, said columncomprising a pair of longitudinally extending structural elementsarranged in parallel relation having the opposing longitudinal surfacesspaced slightly apart and a third longitudinally extending structuralelement abutting and arranged perpendicular to said pair of structuralelements, said pair and said third structural elements being ofsubstantially equal length, said third structural element forming saidlaterally extending vertical edge portion.
 2. The load supporting cornerpost defined in claim 1 wherein said upper and lower generally flat endcaps each has a horizontal cross section of rectangular configuration.3. The load supporting corner post defined in claim 1 wherein saidstructural elements and said end caps are made from wood.
 4. The loadsupporting corner post defined in claim 3 wherein the end caps aresecured to the column by nails driven through the end caps and firstzones into the column.